Hung ceiling electrical box assembly



April 1, 1958 KARLIN 2,328,882

HUNG CEILING ELECTRICAL BOX ASSEMBLY Filed Sept. 2. 1955 32 I a ww 0 7 M United States Patent Q 7 HUNG CEILING ELECTRICAL BOX ASSEMBLY Irving P. Karlin, Great Neck, N. Y.

Application September 2, 1955, Serial No. 532,175

7 Claims. (Cl. 229-392) The present invention relates to an electrical junction box assembly. It is understood, however, that the present invention has a broader application to electrical box construction in general.

It is among the objects of the present invention to pro vide an improved electrical junction box construction in continuous strip of metal and stamped, shaped and cut incidental to the forming operation until a complete box with the overlapping edge portions form a junction therein.

The present invention is particularly directed to hung ceiling boxes where a box is suspended from horizontal ceiling structure members by parallel transverse bars or rods which extend through the side walls of the box and project on either side thereof.

It is among the particular objects of the present invention to provide such a box construction in which the box structure may be so formed and shaped as to enable the box to be locked or jammed in a predetermined fixed position upon said hanging transverse members.

Still further objects and advantages will appear in the more detailed description set forth below, it being understood however that this more detailed description is given by way of illustration and explanation only and not by way of limitation, since various changes therein may be made by those skilled in the art without departing from the scope and spirit of the present invention.

In accomplishing the above objects according to one embodiment of the present invention, the box is stamped and cut from a continuous strip of metal with there being opposite 6 recesses and 2 sides of the box to receive the suspended rods or bars.

Intermediate of these recesses, which are desirably placed to one side of the bend or fold lines, are positioned tab or insertable or depressable members which may be pressed against the rods or bars to hold them in position.

These tabs may take various shapes or forms but in the preferred invention a U-shaped recess is provided the tongue of which may be turned inwardly to grip the suspension bar extending through the box and hold the box in fixed position.

With the foregoing and other objects in view the in vention consists of the novel construction, combination and arrangement of parts as hereinafter more specifically described, and illustrated in the accompanying drawings, wherein is shown an embodiment of the invention, but it is to be understood that changes, variations and modifications can be resorted to which fall within the scope of the claims hereunto appended.

2,828,882 Fatented Apr. 1, 1958 In the drawings wherein like reference characters denote corresponding parts throughout the several views:

Fig. 1 is a plan view of a blank which may be stamped out of a sheet of metal and from which the final box structure may be formed.

Fig. 2 is a top plan view of the covered box structure upon an enlarged scale as compared to Fig. 1, showing the suspension rods extending therethrough and the tabs turned inwardly for locking purposes.

Fig. 3 is a side elevational view of the box of Fig. 2.

Fig. 4 is a side elevational view of the unit of Fig. 2 showing one of the bars inclined obliquely toward the observer.

Figs. 5, 6, 7 and 8 are fragmentary side elevational views of alternative locking tab constructions.

Referring to Figs. 2 to 4 there is shown a box A having the cover B, the parallel suspension bars or rods D and the locking tabs E.

In Figs. 5, 6, 7 and 8 there are shown alternative locking tabs F, E, H and J.

The box is held together by the overlap K and the engagement tongues L.

Referring to the blank in Fig. 1 there are shown the side wall sections 10, 11, 12, 13, 14, 15, 16 and 17 for an octagon cross-section box. Each of these wall sections are provided with the upper and lower knockouts 18 and 19.

The end wall is provided with the slots 20,21 and 22 which receive the tongues 23, 24 and 25. The tongues are provided with reenforcement projections at the top and bottom as indicated at 26 and 27, and'the central tongue 24 is enclosed by the projecting portions 28 and 29.

These projections 26, 27, 28 and 29 alongside of the locking tongue 23, 24, 25 will reenforce said tongues and assure a more rigid box construction.

In forming the box the metal is first stamped out as indicated in Fig. l and then by a series of operations the walls are folded toward each other along the fold lines 38, 31, 32, 33, 34, 35 and 36 until a substantially complete octagon results, as shown in Figs. 2 to 4, whereupon the tongues 23, 24 and 25 are automatically inserted through and folded beyond the openings 20, 21 and 22 as indicated in Figs. 2 and 4.

There will be sufficient opening or space as indicated for assembly at 37 in Fig. 4 to assure that the tongues 23, 24 and 25 will readily be engaged in and through the openings to 22 prior to the final shaping of the box to its octagon size of Figs. 2, 3 and 4 and also to permit a sufiicient location of the end of the tongues 23, 24

and to the wall edge 38 which will give the maximum box strength.

In the walls 10, 12, 14 and 16 there will be stamped the openings 39, 40, 41 and 42 which will extend slightly across the bend lines 30, 31, 34 and and into the area of the walls 11 and 15 as indicated at 43, 44, and 46.

Between the recesses 39 and 40 and 41 and 42 will be stamped tongue structures E which are formed by cutting out U-shaped slots 47 and 48 in the center of the walls 11 and 15 between the upper and lower knockouts 18 and 19 and between the slots 39 and 40 at one side of the box and 41 and 42 at the other side of the box.

These tongues E are a particular feature of the present invention inasmuch as they permit locking of the box in position in respect to the suspended bars D.

Along the edges of the box will be the cover engaging tongues 49 and 50 extending from the edge 51 of the blank and there will also be the holed or tapped lugs 52 and 53 from the edge 54.

These lugs 52 and 53 desirably have side recesses 55 and 56 as shown best in Fig. l.

The cover B desirably consists of a rounded corner 2* plate with the opposite recesses 70 and 71 which receive the tongues 49 and 50 holding said cover-in position.

It will be noted that the tongues 49 and 50 are offset by at least a complete wall section from the opposite holed lug extensions 52 and 53 which are indicated in solid lines at 52 in Fig. 2 and in dotted lines at 53 in Fig. 2.

In the final box construction as shown in Fig. 2 the axis of the lugs 52 and 53 will extend through the center of the box at 72 and be at right angles to the axis which extends through the locking members 49 and St The cover B has the knockouts 72, 73, 74 and 75 and it has a central cup member 76 having the central cup 77 and the cars 78 and 79 which may be riveted in position by the rivets 81 and 82.

it will be noted that the cover has projecting portions at 83 and 84 as well as at the portions which receive the locking tongues .49 and 50 in the slots 70 and 71.

A particular feature of the present invention resides n t e ocking lugs or elements E. The bars as indicated at D in Fig. 2 may be readily inserted through the openings 39 and 40 on one side of the box and 41 and 42 on the other side of the box.

When these bars are inserted in position they may be bent on either sides of the openings 39 and 40 and then the tabs E may be pressed inwardly as indicated in Fig. 2 to provide a fixed arrangement which will eliminate sliding movement of the junction box upon the bars D.

It is thus apparent by the blank as shown in Fig. l and the structure as shown in Figs. 2, 3 and 4 that there is provided a novel and unique hung ceiling junction or electrical connection box in which the final box may be formed as a single unit by automatic machinery, and in which there may be an overlap K provided which will enable automatic engagement of the tongues 23, 24 and 2 with the holes 20, 21 and 22.

The turning in of the tabs B after insertion of the bars D will enable fixing of the hung boxes at any desired adjusted position without any inadvertent movement thereafter when the wiring has once been installed.

In the alternative tab arrangement of Fig. 5, two screwdriver slots 9i) and 91 are provided which enable the upper tongue 92 and the lower tongue 93 to be bent inwardly along the pivotal cut lines 94 and 95 and on g the necks 96 to lodge or press upon the upper and lower edges of the bars D.

In the alternative construction of Fig. 6, there is a double U-shaped slot 97 and 98 forming an S which provides the opposite tongues 99 and 100 which may i be turned inwardly to press against the bar D from opposite directions.

In the arrangement shown in Fig. '7 there is a U-shapcd slot 101 with the end extensions H 2 leaving a neck 103 upon which the tab 104 may be bent inwardly against the bar D.

In the arrangement of Fig. 8 the neck 105 will enable the circular shaped member 196 to be bent inwardly by means oftinsertion in the slot 107 and permit a locking arrangement to be accomplished in this manner.

It is thus apparent that the applicant has provided a complete hung ceiling box construction with an integral locking device Which may be employed for locking the box in position upon the ceiling and preventing it from inadvertently moving out of position once it has been set, as a result of a junction assembly.

While there has herein been illustrated and described the preferred embodiment of the invention, it is to be understood that applicant does not limit himself to the precise construction herein disclosed, and the right is reserved to allchanges and modifications coming within the scope of the invention as defined in the appended claims.

Having now particularly described and ascertained the 4 nature of the invention, and in what manner the same is to be performed, what is claimed is:

l. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side wall sections of said box being formed of a series of rectangular members with fold lines positioned at the meeting edges of said wall sections said box having opposite pairs of slots positioned at and extending across said fold lines, parallel suspension bars extending interiorly of said box and closely adjacent to the interior face of one of said side wall sections and through said slots at the sides of the box and locking means at each side of said box between said slots positioned substantially in the middle of the last mentioned wall section.

2. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side wall sections of said box being formed of a series of rectangular members with fold lines positioned at the meeting edges of said wall sections said box having opposite pairs of slots positioned at and extending across said fold lines, parallel suspension bars extending interior-1y of said box and closely adjacent to the interior face of one of said side wall sections and through said slots at the sides of the box and locking means at each side of said box between said slots positioned substantially in the middle of the last mentioned wall section, said locking means being provided by forming U-shaped recesses in each side of the box with intervening tabs which may be bent inwardly to contact said bars.

3. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side wall sections of said box being formed of a series of rectangular members with fold lines positioned at the meeting edges of said wall sections said box having opposite pairs of slots positioned at and extending across said fold lines, parallel suspension bars extending interiorly of said box and closely adjacent to the interior face of one of said side wall sections and through said slots at the sides of the box and locking means at each side. of said box between said slots positioned substantially in the middle of the last mentioned wall section, said slots extending substantially to and slightly across a fold line between the walls and said locking means consisting of integral tongues bent out of the side walls of the box and necked to the walls of the box.

4. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side. wall sections of said box being formed of a series of rectangular members with fold lines positioned at the meeting edges of said wall sections said box having opposite pairs of slots positioned at and extending across said fold lines, parallel suspension bars extending interiorly of said box and closely adjacent to the interior face of one of said side wall sections and through said slots at the sides of the box and locking means at each side of said box between said slots positioned substantially in the middle of the last mentioned wall section, the ends of the box being overlapping and having inter-locking tongues extending through space recesses in the edge of the box, with the tongues extending substantially to said edge of the. box.

5. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side wall sections of said box beingformed of a series of rectangular members with fold lines positioned at the meeting edges of: said wall sections said box having opposite pairs of slots positioned at and extending acrosssaid fold lines, parallel suspension barsextending interiorly' of; said box and closely adjacent to the interior faceof one of said-side wallsections and through said slots at the sides of the'box and; locking means at each side of said box between said slots positioned substantially in the middle of the last mentioned wall section, said locking means consisting of integral tongues necked to the side wall of the box and designed to be bent against said bars by means of a screwdriver receiving slot.

' 6. A hung ceiling electrical junction box construction of the type folded into polygonal shape from a single integral strip of metal, the side wall sections of said box being formed of a series of rectangular members with fold lines positioned at the meeting edges of said wall sections said box having opposite pairs of slots positioned at and extending across said fold lines, parallel suspension bars extending interiorly of said box and closely adjacent to the interior face of one of said side wall sections and through said slots at the sides of the box and locking means at each side of said box between said slots positioned substantially in the middle of the last mentioned wall section, said locking means being provided by forming a U-cut in the side walls of the box opposite said bars, forming inwardly bendable tongues to press against said bars.

7. A vertical tubular octagonal cross section hung ceiling electrical box comprising a single rectangular sheet of metal having its maximum dimension positioned horizontally and a plurality of vertical fold lines spaced so as to form eight rectangular sides when the blank is folded into the box, one pair of opposite parallel sides having slots in median portions thereof extending principally through the adjacent oblique sides and then slightly through the fold lines into the side edge portions of the opposite parallel sides, opposite parallel fiat metal hanger strips extending through said slots and into the interior of said box and parallel to the interior faces of said opposite side but slightly spaced from said faces and means in the middle portion of said opposite faces to engage said strips frictionally and hold them in position.

References Citedin the file of this patent UNITED STATES PATENTS Buckels Feb. 3, 1931 

